Journal of Natural Gas Science and Engineering 34 (2016) 670e679

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Journal of Natural Gas Science and Engineering

journal homepage: www.elsevier.com/locate/jngse

Cuttings transport behavior in directional drilling using computational

uid dynamics (CFD)
Behnam Amanna, Mohammad Reza Khorsand Movaghar*
Petroleum Engineering Department, Amirkabir University of Technology, Hafez Ave., No. 424, Tehran, Iran

a r t i c l e i n f o a b s t r a c t

Article history: As one of the most crucial concerns in hole cleaning and especially in directional drilling, cutting
Received 14 May 2016 transport optimization eventuates in the reduction of drilling costs and increase in oil recovery. Cutting
Received in revised form removal is, however, affected by different parameters including uid ow rate, drill pipe rotation, cutting
10 July 2016
size and inclination which have to be considered simultaneously. In the current report, Liquid-Solid
Accepted 13 July 2016
model is implemented to solve the governing equations in the Eulerian CFD framework. Results are
Available online 16 July 2016
compared with experimental data and successful validation with experimental data is achieved. On the
basis of design of experiment algorithm, further simulations have been carried out to investigate the
Keywords:
Hole cleaning
effect of the as mentioned key parameters on cutting transport behavior. Results show that hole in-
Cutting transport clinations between 45 and 60
are the most difcult angles in hole cleaning process. Moreover, increase
Computational uid dynamic in values of ow rate and drill pipe rotation will effectively improve the drag effects leading to superior
Hole inclination cutting removal. Besides, it has been proven that cutting size affects cutting transport less than the other
Pipe rotation parameters. For industrial applications, an empirical correlation is developed for estimating cutting
concentration. Buckingham-p theorem along with multi-variable regression technique is applied to
establish the correlation.
2016 Elsevier B.V. All rights reserved.

1. Introduction Further studies on the impact of hole inclination in drilling

Accumulation of drilled cuttings in the bottom of the well
through the drilling process may cause several problems such as
stuck pipe, increase in torque, exhaustion of the drill and most
important of all, considerable decrease in drilling rate which leads
to extended drilling periods and raised drilling costs. In order to
bring drilling cuttings out of the hole, it is necessary to overcome
gravitational forces. Further-more, the key parameters affecting the
formation of the cutting bed in the annulus should also be explored
to achieve an ideal cleaning.
Several studies have been devoted to hole cleaning and trans-
portation of drilling cuttings in the experimental elds and through
CFD simulation. Investigations by Zeidler, 1970, as one of the pio-
neers in studies on the transportation of drilling cuttings, on the
parameters affecting cutting transport including ow rate of dril-
ling mud and drill pipe rotation prove that turbulent ow and pipe
rotation improve hole cleaning performances.
* Corresponding author.
E-mail address: m.khorsand@aut.ac.ir (M.R. Khorsand Movaghar).
cutting transport phenomena by Okranjni and Azar, 1985 suggested
the angles in the 45e55
range to be critical for particles transport
where hole cleaning is more difcult. Brown et al. have reported the
angles between 50 and 60
to be the most difcult angles in hole
cleaning process through experiments in the BP research center.
(Peden et al., 1990) with the use of equipment of Herriot-Watt
University, studied on the impact of changes in the inclination
angle and drill pipe rotation as well as the size of the cuttings on the
drilling cuttings transport, have proven the drill pipe rotation to
vastly impact transmission of the cuttings; Regardless of the drill
pipe rotation, however, angles between 40 and 60
were found to
be the hardest angles to transfer drilling cuttings. Transfer of small
sized cuttings in comparison to larger particles was also proved to
be more difcult in all drilling angles.
As with the analysis on the effect of particle size (Sifferman and
Becker, 1992), in the southwest research center have proved that in
angles close to horizontal state and with low diameter particles,
drill pipe rotation has a huge impact on the removal of the particles
out of well. Studies by Bassal, 1995 on the impact of particle size on
transportation and hole cleaning based on particles between 2 and
7 mm in diameter also exhibited that hole cleaning and transfer of

http://dx.doi.org/10.1016/j.jngse.2016.07.029
1875-5100/ 2016 Elsevier B.V. All rights reserved.
 B. Amanna, M.R. Khorsand Movaghar / Journal of Natural Gas Science and Engineering 34 (2016) 670e679 671

smaller particles to be more difcult than larger ones.

Martins et al., 1996 undertook the same experiments as Bassal m_ pq m_ qp (2)
on particles in the 2e6 mm diameter range, however and in
contrast to former deductions by Bassal, transfer of larger particles m_ pp 0 (3)
were reported to be more difcult than smaller ones.
Through investigations on the rotation of drill string and its The momentum balance for gas phase q yields:
impact on the transportation of drilling cuttings using particles 
sized between 2 and 7 mm, Sanchez et al., 1999 concluded that vaq rq !
yq
orbital motion of the drill pipe has a dramatic impact on the V$aq rq ! y q aq VP V$tq aq rq !
y q! gg
transfer of drilling cuttings, especially at low angles; High speed vt
rotation of the drill string and the use of high viscous uids, were X
N   
Kpq !yp !
yq
also suggested to be easier in carrying ner particles.
p1
Regarding CFD investigations on transport of cuttings, Bilgesu 
! !
(Bilgesu et al., 2002) reported that drill string rotation, especially in m_ pq !
y pq aq rq F q F lift;q
particles with smaller diameters has a great inuence on hole ! 
cleaning. Through reviews on various angles, inclination angle was F ym;q
also proved to have a great impact on transportation of drilling (4)
cuttings. Mishra, 2007 used the Eulerian model to simulate the
drilling cuttings transport in the CFD eld. The results showed that where tq is the qth phase stressestrain tensor is given as:
reductions in the inclination angle, will lead for transportation of
the drilling cuttings out of the annulus space to be more difcult.
  
2
tq aq mq V!
y q V!
y q aq lq  mq V$!
T
Investigations by Mishra further exhibited that drilling uid ow y qI (5)
3
has a great impact on the hole cleaning and proved that the larger
particles to be more easily carried in water than smaller ones. here mq and lq are the shear and bulk viscosity of phase q, Fq is an
Conclusions similar to results by Bilgesu were taken on the impact external body force, Flift,q is a lift force, Fvm,q is a virtual mass force,
of drilling pipe rotation. Li et al., 2009 investigated the impact of Kpq is the interphase momentum exchange coefcient, P is the
drill pipe rotation on cuttings transportation in CFD. The as pressure shared by all phases and npq is the interphase velocity. The
mentioned simulations showed that drill pipe rotation has a large momentum equation for solid phase is described as follow:
inuence on disturbance of the annulus space as well as in reducing
the cutting concentration in the annulus space and accelerating the vas rs !
y s
cuttings and speeding-up their exit out of the hole. V$as rs !
y s!
y s as VP  VPs V:tq
vt
Investigating on different parameters of drilling cuttings trans- N

!X
portation has provided researchers with deep insights into the as rs g Kls !
yl!
y s
process. In this study, by using the CFD tools, the effects of key p1
parameters including the ow of drilling uid, particle size, the drill 
! !
string rotation and the inclination angle on the cutting transport m_ lq !
y ls as rs F s F lift;s
behavior will be dis-cussed. To this purpose, simulation models are ! 
F ym;s
primarily veried with a series of experimental results. Using the
design of experiments algorithm, different scenarios are then (6)
modeled with CFD simulator. Since one of the most important goals
related to studies of drilling cutting transportation is to reduce the where Ps is the solid pressure, composed of a kinetic term and a
problems related to directional drilling, the main purpose of this term due to particle collisions, Kls Ksl is the momentum exchange
study was to evaluate the effect of the inclination angle in cutting coefcient between liquid and solid phases shown as l and s
transport behavior. respectively, N is the total number of phases, and Fs, Flift,s and Fvm,s
are different forces exerted on the solids and dened earlier. In the
above equations a is volume fraction and can be dened as follow:
2. Mathematical modeling
Z
Two-uid model is used for simulation of Liquidesolid ow in y adV (7)
the annulus of a well. Governing equations for liquidesolid ow are V
presented in the EulerianeEulerian framework in which the par-
Momentum equation in fully turbulent ow is determined from
ticles and liquid are assumed as continues phases. The liquid and
K- model (Shih and Liou, 1995) in which the effective viscosities in
particles behaviors can be predicted by solution of the governing
the case of two-phase ow type have been estimated from this
partial differential equations in three-dimensional cylindrical co-
model. Hereupon, the effective viscosity correlations for the liquid
ordinate system. Coordinate system is xed and particles pass
phase are as follow:
through the xed control volumes. The governing equations of this
model are as follow.
The continuity equation for phase q is given as follow:
mEff m mtl (8)


v aq rq
 Xn cm rl Kl2
V$ aq rq !
yq m_ pq (1) mtl (9)
vt l
p1

Where nq is the velocity of phase q and m_ pq characterizes the

Cm 0:09 (10)
mass transfer from the pth to qth phase. From the mass conser-
vation equation we can obtain: And for solid phase are:
672 B. Amanna, M.R. Khorsand Movaghar / Journal of Natural Gas Science and Engineering 34 (2016) 670e679
mEff m mts (11)
cm rs Ks2
mts (12)
s
Cm 0:09 (13)
where m is dynamic viscosity, Cm is a dimensionless constant
assumed to be 0.09, r is the density for corresponding/related
phase, K is turbulent kinetic energy and s is turbulent dissipation
energy.
The above partial differential equations are coupled and
nonlinear, and can only be solved by numerical methods.
In this study, CFD Software is used for numerical solution of the
governing partial differential equations as a means for cutting
transport simulation in the wellbore annular space.
3. Methodology
3.1. Mesh
Gambit (Fluent 6.2 Documentation) software is used to
construct and to mesh the model geometry. Geometry includes
coaxial pipes in which inner pipe is assumed as drilling pipe while
outer pipe as casing and has is versatile alike the experimental set
up. It is worth noting that in simulated model, inner pipe as a drill
pipe rotates like experimental model. According to Fig. 1 Total
number of simulated meshes in a 4 meters section is about 250400
and is kind of Quad Map on area and Hex Wedge/Cooper in volume.
3.2. Boundary conditions
Velocity inlet as inlet and pressure outlet as outlet are imple-
mented as the boundary conditions for turbulent ow. The outer
pipe is considered as a stationary wall with no-slip condition
(because of stationary casing pipe) while rotational wall has been
considered for inner pipe (due to drill pipe rotation as moving
wall).
Here, water is supposed as carrier or drilling uid as rst phase
Fig. 1. Mesh generated for the annular section.
and cutting as the second phase. Volume percentage of cuttings in
the entrance is considered to be constant and about 6%, with a
density of 2700 kg/m3 in various sizes from 2 to 8 mm as experi-
mental set up. Properties of solid particles as well as granular form
were estimated through the kinetic theory. Moreover, due to the
presence of solid and liquid phases, Eulerian model was selected
among the other two-phase models to investigate the cutting
transport behavior.
In this simulation, rate of cutting transport through hole is
investigated by changing effective parameters on hole cleaning
consisting of ow rate of drilling uid, drill pipe rotation, size of
cutting and inclination.
3.3. Model verication
For accuracy, simulation results were compared with the ex-
periments which were performed in the Drilling Laboratory of the
Tehran Polytechnic University in Petroleum Engineering Depart-
ment. The experimental set up consists of two pumps for uid and
cutting injection, an electromotor for rotating drill pipe (inner
pipe), pressure gauge, a mixer tank as a feed storage for injecting
pumps, a metal structure to ease changing the tube angle, a four
meter length transparent pipe with 4 1/8 00 diameter as the casing
and 2 1\400 diameter pipe in-side it as the drilling pipe. The exper-
imental simulator and the schematic of applied cutting transport
simulator is demonstrated in Figs. 2 and 3.
Specications of equipment and properties of uid are
mentioned in Table 1.
Lab drilling device was established based on dimensional
analysis according to condition of 95/800 section appeared in Khar-
tang discovery well in Khartang eld in south of Iran. In this regard,
the ratio of internal diameter to external diameter (the diameter of
drill pipe to casing), type and size of cuttings are adjusted to drilling
device located in Khartang eld.
Four tests have been taken in laboratory by considering 60

angle, cutting size of 5 mm diameter, pipe rotation of 60 rpm and
different ow rates and corresponding CFD simulations have then
been performed.
Comparing the curves referring to simulation and experimental
results in Fig. 4, a 5.94% absolute average error is observed. As so,
well conrmation is achieved for the accuracy of simulation results.
 B. Amanna, M.R. Khorsand Movaghar / Journal of Natural Gas Science and Engineering 34 (2016) 670e679
Fig. 2. AUT-PETE experimental setup of cutting transport simulator.
3.4. Design of experiment
To investigate the variations in key parameters, further testing
and simulation should be done.
In order to decrease the cost of time-consuming experiments, an
optimized design should be obtained for carrying out the simula-
tion scenarios. On this basis, the values for effective parameters are
then chosen as a result of design of experiments (DOE) algorithm.
To this purpose, the carefully veried CFD simulated model from
the last section was implemented along with DOE data. The cor-
responding 25 runs are then performed in accordance with DOE
parameter sets in Table 2.
After running simulations based on the DOE, correlations should
be achieved to predict cutting transport behavior in annular
space and generally the effect of impressive parameters on the
hole cleaning process. These correlation, are introduced as graphs
in the next section.
Fig. 3. Schematic of AUT-PETE Experimental setup for cutting transport simulator.
673
Table 1
Specications of experimental equipment and properties of uid.
Drill pipe diameter 2 1/4
Casing diameter 4 1/8
Cutting density 2700
Drilling uid ow rate 40e60e80e90
Hole inclination 60
Cutting diameter 5
Inlet cutting volume fraction 0.06
Drill pipe rotation speed 60
4. Result and discussion
4.1. Effect of ow rate and cutting size on concentration of cuttings
As observed in Figs. 5 and 6, accumulation of cuttings in the
annular space, which cause severe problems during the drilling
procedure, increases as the drilling mud ow rate decreases. As
expected, increase in ow rates will strengthen the intensity of
turbulent eddies which result in the lift of cuttings into the
dispersed layer. Therefore, only pure drilling uid layer and dispersed
layers will exist. With further increases in ow rates, cuttings will
be transported out of annular space.
Based on these gures, at higher ow rates of drilling mud, the
effect of particle size on hole cleaning is more obvious. This is due to
the lack of sufcient drag force being implemented on particles at
lower rates.
Comparing Figs. 4 and 5, it can be seen that at the same ow
rate, particle size and drill string rotation, more accumulation of
cuttings occurs at the angle of 60
relative to the angle 30
.
4.2. Effect of ow RPM and cutting size on concentration of cuttings
As can be understood from Figs. 7 and 8, the effect of RPM on
hole cleaning is similar to drilling mud ow rates. Hole cleaning is
improved at higher drill string rotational speeds. The effect of RPM
on hole cleaning is due the drag forces applied to cuttings by
viscous forces. Such a drag force is caused by tangential velocity of
drilling mud as the drill string rotates. Therefore, at higher veloc-
ities, larger drag forces on cuttings are experienced which leads to
superior hole cleaning.
As observed in Figs. 7 and 8, changing the hole angle from 30 to
60
will increase the cutting accumulation in the annular space.
674 B. Amanna, M.R. Khorsand Movaghar / Journal of Natural Gas Science and Engineering 34 (2016) 670e679

Fig. 4. Comparison of cutting concentrations from model prediction with lab data.

4.3. Effect of inclination on concentration of cuttings
Fig. 9 simultaneously shows the effect of inclination and RPM on
hole cleaning at an averaged ow rate of 70 GPM. Fig. 10 also
demonstrates the effect of ow rate on hole cleaning at an averaged
RPM of 60, as the inclination changes. In both gures, particles have
a diameter of 5 mm.
In spite of the previous results, particle concentration shows a
polynomial behavior with respect to changes in inclination and the
trend is no more linear. Within the range of 45e60
, a maximum
value of cutting volume concentration is experienced. This range of
hole angles is referred to as critical area. During drilling
operations, careful considerations should be given to critical angles
in order to prevent formation of cutting beds. Similar observations
have been proposed by Fig. 11.
4.4. Contours of cutting concentration
For further investigations on the effects of operational param-
eters on hole cleaning, contours of cutting concentrations have
been presented at two hole angles of 30 and 60
. Side bars in these
gures present cutting concentrations where red and blue colors
refer to maximum and minimum concentrations, respectively.
As observed in Figs. 12 and 13, the concentration of cuttings in

Table 2
Variables of design of experiment.

Run NO. Flow rate (GPM) Inclination (degrees) Cutting size (mm) Drill pipe rotation (RPM)

1 70 60 5 30
2 70 60 8 50
3 50 60 5 50
4 60 75 6.5 60
5 80 45 6.5 60
6 70 60 2 50
7 90 60 5 50
8 60 45 3.5 40
9 80 75 3.5 60
10 70 60 5 70
11 80 45 6.5 40
12 80 75 6.5 40
13 60 45 6.5 40
14 60 75 6.5 40
15 80 45 3.5 60
16 60 45 3.5 60
17 60 75 3.5 60
18 60 75 3.5 40
19 80 75 3.5 60
20 70 30 5 50
21 80 45 3.5 40
22 60 45 6.5 60
23 70 60 5 50
24 70 90 5 50
25 80 75 3.5 40
 B. Amanna, M.R. Khorsand Movaghar / Journal of Natural Gas Science and Engineering 34 (2016) 670e679 675

Inc=30,RPM=60
0.45

0.4

Total Cutting Volume Concentration(%)

0.35

0.3

0.25
siz = 2

siz = 3.5
0.2
siz = 5

siz = 6.5
0.15
siz = 8

0.1
50 55 60 65 70 75 80 85 90
Flow rate(gpm)

Fig. 5. Effect of ow rate on cutting concentration for different cutting sizes, inclination of 30
and drill string speed of 60 RPM.

the annular space decreases as the ow rates increase from 60 to 80 of annulus. As formerly described, the difference between the
and also with RPM increases from 30 to 70. According to the con- concentration of cuttings at inclinations of 30 and 60
can be
centration contours, drilling cuttings have an asymmetric distri- observed in Figs. 12 and 13.
bution and cutting beds will be simply formed at relatively low
RPMs and ow rates. As larger drag forces applied to particles
caused by drill string rotation in the vicinity of drill string, the 5. Empirical correlation
accumulation of cuttings is more obvious near the casings. Larger
RPMs moves the cuttings out of the bed to the dispersed layer As discussed in the previous sections, cutting concentration is a
where higher ow rates improve the transportation of cuttings out function of many parameters and can be dened as:

Inc=60,RPM=60
0.4
Total Cutting Volume Concentration(%)

0.35

0.3

0.25 siz = 2

siz = 3.5

siz = 5
0.2
siz = 6.5

siz = 8

50 55 60 65 70 75 80 85 90
Flow rate(gpm)

Fig. 6. Effect of ow rate on cutting concentration for different cutting sizes, inclination of 60
and drill string speed of 60 RPM.
676 B. Amanna, M.R. Khorsand Movaghar / Journal of Natural Gas Science and Engineering 34 (2016) 670e679

Q=60,Inc=30
0.34

0.33
Siz= 2
Total Cutting Volume Concentration(%)

0.32

Siz= 3.5
0.31

0.3 Siz= 5

0.29
Siz= 6.5

0.28

Siz= 8

0.27
30 35 40 45 50 55 60 65 70 75 80
RPM

Fig. 7. Effect of drill string speed on cutting concentration for different cutting sizes, inclination of 30
and ow rate of 60 GPM.

Q=60,Inc=60
0.345

0.34
Total Cutting Volume Concentration(%)

0.335
Siz= 2

0.33
Siz= 3.5

0.325

Siz= 5
0.32

0.315 Siz= 6.5

0.31
Siz= 8

0.305
30 35 40 45 50 55 60 65 70 75 80
RPM

Fig. 8. Effect of drill string speed on cutting concentration for different cutting sizes, inclination of 60
and ow rate of 60 GPM.

Vb n2
f q; n; u; rl ; rs ; m; Dh ; g; dc (14) p2 (16)
VW gDhyd
Based on Buckingham-p theorem, seven dimensionless groups
are determined as follows (Ozbayoglu et al., 2008):
p3 Cc (17)
rnDhyd
p1 (15)
m p4 q (18)
 B. Amanna, M.R. Khorsand Movaghar / Journal of Natural Gas Science and Engineering 34 (2016) 670e679 677

Q=70,Siz=5
0.3

0.28

Total Cutting Volume Concentration(%)

RPM= 40
RPM= 50
RPM= 60
0.26 RPM= 70
RPM= 80

0.24

0.22

0.2

0.18
0 10 20 30 40 50 60 70 80 90
Inc

Fig. 9. Effect of inclination on cutting concentration for different drill string speeds, ow rate of 70 GPM and cutting size of 5 mm.

RPM=60,Siz=5
0.45

0.4
Total Cutting Volume Concentration(%)

0.35
Q= 50

0.3 Q= 60

Q= 70
0.25
Q= 80

0.2
Q= 90

0.15

0.1
0 10 20 30 40 50 60 70 80 90
Inc

Fig. 10. Effect of inclination on cutting concentration for different ow rates, drill string speed of 60 RPM and cutting size of 5 mm.

stands for pipe rotation (s-1), rl is the density of drilling uid (kg/
p5
dc
(19) m3), rs is the density of cuttings (kg/m3), m represents the viscosity
Dhyd of drilling uid (Pa/s), dc is the cuttings size (m), Dhyd stands for the
hydraulic diameter (m), Cc is the cuttings concentration, g stands
dc rn for the gravity (N/kg).
p6 (20) In related experimental condition and simulations, injected
m
cuttings concentrations is constant, so the term p3 is neglected and
Eq. (14) is changed to:
uDhyd
p7 (21)
n Vb
a1 pa12 pa23 pa44 pa55 pa66 pa77 (22)
VW
where Vb represents cuttings volume (m3), Vw is wellbore volume
(m3), q is the inclination (
), v represents uid ow rate m/s, x The multi-variable regression technique is applied for data from
678 B. Amanna, M.R. Khorsand Movaghar / Journal of Natural Gas Science and Engineering 34 (2016) 670e679

Fig. 11. Hole cleaning difculty vs. inclination (Swaco).

Fig. 13. Annular cuttings concentration contour at the angle of 30.

respect to experimental data was successfully carried out. Results

are presented as follow:

- Hole inclinations between 45 and 60
as critical angles cause the

cutting removal to be more difcult.
- Cutting concentration in annular space decreases with
increasing uid ow rate due to the strengthened intensity of
eddy turbulent ow. Therefore, at higher ow rates of drilling
mud, the effect of particle size on hole cleaning is more evident.
- Cutting removal is more convenient for larger cutting particles.
- Due to greater drag forces applied to cuttings, transportation of
cuttings will be easier at higher drill pipe speeds.
Fig. 12. Annular cuttings concentration contour at the angle of 60. - Buckingham-p theorem was applied to dene dimensionless
groups as an empirical correlation for estimating cutting con-
centration using multi-variable regression techniques for
25 groups, and cuttings concentration can be determined:
Khartang eld based on CFD simulations.
  !0:060079
Vb rnDhyd 0:17759 n2
7:9664 Nomenclatures
VW m gDhyd
!0:92395 r Fluid density [Kg/m3]
0:009657 dc (23) m
q Dynamic viscosity [gr/cm S]
Dhyd p Dimensionless group
 1:0048  0:060668 q Inclination [degrees]
rndc uDhyd u drill string rotation [RPM]
m n Q Fluid ow rate [GPM]
CC Cutting concentration
n Fluid velocity [m/s]
6. Conclusion d Diameter [inch.]

In this paper, two-phase liquidesolid ow in the annular space References

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